20 hp to 200 hp @ 460 vac 20 hp to 150 hp @ 575 vac · instruction manual sp600 ac drive user...

Instruction Manual

SP600 AC DriveUser ManualVersion 3.0

6SB401 Series

20 HP to 200 HP @ 460 VAC

20 HP to 150 HP @ 575 VAC

D2-3501-5

©2004 Rockwell Automation. All rights reserved.

The information in this manual is subject to change without notice.

Throughout this manual, the following notes are used to alert you to safety considerations:

Important: Identifies information that is critical for successful application and understanding of the product.

The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to signify new or revised text or figures.

!ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

ControlNet is a trademark of ControlNet International Ltd.DeviceNet is a trademark of Open DeviceNet Vendor Association.SP600, VS Utilities, and Reliance are trademarks of Rockwell Automation.

!

ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this document in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.ATTENTION: DC bus capacitors retain hazardous voltages after input power has been removed. After disconnecting input power, wait five minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: The drive can operate at and maintain zero speed. The user is responsible for assuring safe conditions for operating personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating, or may operate, at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss or life.ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution can result in bodily injury.

ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuitry must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.ATTENTION: The user is responsible for conforming with all applicable local and national codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Contents I

CONTENTSChapter 1 Introduction

1.1 Manual Conventions ...................................................... 1-11.2 Getting Assistance from Reliance Electric..................... 1-1

Chapter 2 About the Drive2.1 Identifying the Drive by Model Number.......................... 2-12.2 Power and NEMA Enclosure Ratings ............................ 2-22.3 Overview of SP600 Features......................................... 2-4

2.3.1 Analog Inputs....................................................... 2-42.3.2 Analog Outputs.................................................... 2-52.3.3 Digital Outputs ..................................................... 2-52.3.4 Multiple Control Modes........................................ 2-52.3.5 Multiple Stop Methods ......................................... 2-62.3.6 Multiple Speed Control Methods ......................... 2-62.3.7 Auto/Manual Reference Selection ....................... 2-62.3.8 Seven Preset Frequency Setpoints ..................... 2-72.3.9 Motor-Operated Potentiometer (MOP) Function . 2-72.3.10Auto Restart (Reset/Run) .................................... 2-72.3.11Autotune .............................................................. 2-82.3.12Drive Protection Current Limit ............................. 2-82.3.13Drive Overload Protection ................................... 2-92.3.14Motor Overload Protection................................. 2-102.3.15 .Shear Pin Fault................................................. 2-102.3.16 .Drives Peripheral Interface (DPI)...................... 2-102.3.17Network Data Transfer via Datalinks ................. 2-112.3.18Programmable Parameter Access Levels and

Protection .......................................................... 2-112.3.19Process PI Loop ................................................ 2-112.3.20S Curve.............................................................. 2-122.3.21Three Skip Bands (Avoidance Frequencies) ..... 2-122.3.22Flying Start ........................................................ 2-122.3.23Voltage Class .................................................... 2-122.3.24 Motor Cable Lengths ........................................ 2-132.3.25 Economizer Mode............................................. 2-132.3.26Fan Curve ......................................................... 2-132.3.27Programmable Parameter Access Levels and

Protection .......................................................... 2-142.3.28User Sets........................................................... 2-14

2.3.28.1Normal Mode...................................... 2-142.3.28.2Dynamic Mode ................................... 2-15

2.4 CE Conformity ............................................................. 2-172.4.1 Essential Requirements for CE Compliance ..... 2-18

2.5 Drive Connections ....................................................... 2-19

II SP600 AC Drive User Manual

2.6 Drive Communication Options ..................................... 2-212.7 Remote Operator Interface .......................................... 2-21

2.7.1 Connecting the Remote OIM or VS Utilities to the Drive................................................................... 2-21

2.8 PC-Based Utility........................................................... 2-22

Chapter 3 Mounting the Drive3.1 General Requirements for the Installation Site .............. 3-2

3.1.1 Verifying Power Module AC Input Ratings Match Available Power................................................... 3-23.1.1.1 Unbalanced or Ungrounded Distribution

Systems ................................................ 3-23.1.1.2 Input Power Conditioning...................... 3-43.1.1.3 AC Input Phase Selection (60HP and

Larger) .................................................. 3-43.1.1.4 Selecting/Verifying Fan Voltage (60HP and

Larger) .................................................. 3-43.1.2 Making Sure Environmental Conditions are Met . 3-53.1.3 Minimum Mounting Clearances ........................... 3-63.1.4 Drive Dimensions and Weights............................ 3-7

3.2 Mounting the Drive....................................................... 3-113.2.1 Verifying the Drive’s Watts Loss Rating............. 3-11

Chapter 4 Wiring Requirements for the Drive4.1 Power Wiring.................................................................. 4-1

4.1.1 Power Wire Sizes ................................................ 4-34.1.2 Using Input/Output Contactors ............................ 4-4

4.2 Control and Signal Wire Sizes ....................................... 4-54.3 Recommended Motor Lead Lengths.............................. 4-5

4.3.1 Reflected Wave Compensation ........................... 4-64.4 Selecting Input Line Branch Circuit Protection............... 4-94.5 Verifying Power Module Output Current Rating is Greater than Motor Full Load Amps........................... 4-9

Chapter 5 Finding Wire-Routing Locations and Grounding5.1 Routing Input, Motor Output, Ground, and Control Wiring

for the Drive ................................................................... 5-15.2 Grounding the Drive....................................................... 5-4

Chapter 6 Installing Power Wiring6.1 Opening the Cover......................................................... 6-16.2 Installing Output Power Wiring....................................... 6-26.3 Installing Input Wiring..................................................... 6-3

6.3.1 Installing an Optional Transformer and Reactor .. 6-36.3.2 Installing Fuses for Branch Circuit Protection...... 6-46.3.3 Installing the Required Input Disconnect ............. 6-4

Contents III

6.3.4 Installing Power Wiring from the AC Input Line to the Drive’s Power Terminals ..................................... 6-4

Chapter 7 Installing Control Wiring7.1 Stop Circuit Requirements............................................. 7-1

7.1.1 User-Initiated Stopping ........................................ 7-27.2 Control and Signal Inputs .............................................. 7-27.3 Removing the I/O Terminal Block .................................. 7-27.4 Wiring the Signal and Control I/O .................................. 7-27.5 I/O Wiring Examples ...................................................... 7-67.6 Wiring Diagram - Control and Motor .............................. 7-77.7 Speed Reference Control ............................................ 7-10

7.7.1 Auto Reference Sources ................................... 7-107.7.2 Manual Reference Sources ............................... 7-107.7.3 Changing Reference Sources ........................... 7-117.7.4 Auto/Manual Control.......................................... 7-11

7.8 Remote OIM Configuration .......................................... 7-12

Chapter 8 Completing the Installation8.1 Checking the Installation................................................ 8-18.2 Powering Up after Installation is Complete.................... 8-2

Chapter 9 Using the Start-Up Routines on the LCD OIM9.1 Preparing for Start-Up.................................................... 9-19.2 Running the Start-Up Routines...................................... 9-2

9.2.1 Sensorless Vector Performance.......................... 9-49.2.2 High Speed Operation (>120 Hz) ........................ 9-5

9.3 Start/Stop Control .......................................................... 9-59.4 Speed Reference........................................................... 9-69.5 Changing the Speed of the Drive (Setpoint Control) ..... 9-6

Chapter 10 Programming Basics10.1About Parameters........................................................ 10-110.2How Parameters are Organized .................................. 10-210.3Accessing the Parameters........................................... 10-3

10.3.1Selecting the Parameter Access Level.............. 10-410.3.2Restricting Access to Other Parameter Levels.. 10-5

10.4Ensuring Program Security.......................................... 10-6

Chapter 11 Parameter Descriptions

Chapter 12 Troubleshooting the Drive12.1Verifying that DC Bus Capacitors are Discharged Before Servicing the Drive ......................................... 12-112.2Determining Precharge Board Status Using the LED

Indicators (Frames 5 & 6 Only) ................................... 12-312.3Determining Drive Status Using the Ready LED ......... 12-4

IV SP600 AC Drive User Manual

12.4About Alarms ............................................................... 12-512.4.1About the Alarm Queue ..................................... 12-512.4.2Alarm Descriptions............................................. 12-6

12.5About Faults................................................................. 12-912.5.1About the Fault Queue..................................... 12-1012.5.2Clearing Faults................................................. 12-1112.5.3Fault Descriptions and Corrective Actions....... 12-12

12.6Common Symptoms and Corrective Actions ............. 12-1912.7Replacement Parts .................................................... 12-2312.8Troubleshooting the Drive Using the LCD OIM.......... 12-23

12.8.1Accessing the Fault Queue.............................. 12-2412.8.2Accessing the Fault Parameters...................... 12-2512.8.3Accessing the Drive Status Parameters .......... 12-2512.8.4Determining the Product Version..................... 12-2612.8.5Contacting Tech Support for Assistance ......... 12-28

Appendix A Technical Specifications

Appendix B Using the LCD OIM

Appendix C Parameters Cross-Referenced by Name

Appendix D Analog Input Selection Path

Appendix E Process PI Block Diagram

Appendix F Record of User Settings: Advanced Access Level

Index

Contents V

List of Figures

Figure 2.1 – Identifying the Drive by Model Number................................... 2-2Figure 2.2 – Normal Mode Operation ....................................................... 2-14Figure 2.3 – Dynamic Mode Operation..................................................... 2-16Figure 2.4 – Drive Connections ................................................................ 2-20

Figure 3.1 – Typical Jumper Locations ...................................................... 3-3Figure 3.2 – Selecting Input Phase and Fan Voltage (60HP and Larger)... 3-5Figure 3.3 – Minimum Mounting Clearances .............................................. 3-6Figure 3.4 – Panel-Mount Drive Dimensions - Frames 2 and 3.................. 3-7Figure 3.5 – Panel Mount Drive Dimensions - Frame 4.............................. 3-8Figure 3.6 – Panel-Mount Drive Dimensions - Frame 5.............................. 3-9Figure 3.7 – Panel-Mount Drive Dimensions - Frame 6............................ 3-10

Figure 4.1 – How to Calculate Typical Motor Lead Lengths ....................... 4-6Figure 4.2 – Inverter and Motor Line-to-line Voltages................................. 4-7Figure 4.3 – Motor Overvoltage as a Function of Cable Length ................. 4-8

Figure 5.1 – Wire Routing and Terminal Block Locations (Frame 2 Shown) .................................................................. 5-2Figure 5.2 – Wire Routing and Terminal Block Locations (Frame 5 Shown) .................................................................. 5-3Figure 5.3 – Typical Grounding................................................................... 5-4Figure 5.4 – Single-Point Grounding/Panel Layout..................................... 5-5

Figure 6.1 – Opening the Drive Cover ........................................................ 6-1Figure 6.2 – Power Terminal Block............................................................. 6-5

Figure 7.1 – Typical Wiring Diagram........................................................... 7-7Figure 7.2 – Wiring Diagram - Default Drive Configuration......................... 7-9Figure 7.3 – Speed Reference Control Flowchart..................................... 7-11Figure 7.4 – Speed Reference Selection .................................................. 7-13

Figure 9.1 – Accessing the Start-Up Routines............................................ 9-2Figure 9.2 – Start-Up Menu ........................................................................ 9-2Figure 9.3 – Start/Stop Control using the Local OIM .................................. 9-5Figure 9.4 – Two-Wire and Three-Wire Start/Stop Control......................... 9-5Figure 9.5 – Analog Speed Reference........................................................ 9-6

Figure 10.1 – Example of Parameter Organization................................... 10-2Figure 10.2 – Accessing the Parameters Using the LCD OIM.................. 10-3Figure 10.3 – Selecting the Parameter Access Level ............................... 10-4Figure 10.4 – Setting the Access Level Password.................................... 10-5Figure 10.5 – Setting the Write-Protect Password.................................... 10-6

VI SP600 AC Drive User Manual

Figure 11.1 – Motor Overload Hertz........................................................ 11-11Figure 11.2 – Custom V/Hz Curve .......................................................... 11-12Figure 11.3 – Fan/Pump Curve............................................................... 11-13Figure 11.4 – Speed Limits ..................................................................... 11-13Figure 11.5 – Compensation (56) ........................................................... 11-14Figure 11.6 – Speed Control Method...................................................... 11-19Figure 11.7 – Speed Limits ..................................................................... 11-20Figure 11.8 – Trim Input Select............................................................... 11-26Figure 11.9 – Trim Out Select (118)........................................................ 11-27Figure 11.10 – PI Configuration (124)..................................................... 11-29Figure 11.11 – PI Control (125)............................................................... 11-31Figure 11.12 – PI Preload Value............................................................. 11-34Figure 11.13 – PI Status (134) ................................................................ 11-35Figure 11.14 – Save OIM Ref (192) ........................................................ 11-51Figure 11.15 – Save MOP Ref (194)....................................................... 11-52Figure 11.16 – Dyn UserSet Cnfg ........................................................... 11-56Figure 11.17 – DynUsrSetSel ................................................................. 11-57Figure 11.18 – Drive Status 1 (209) ........................................................ 11-58Figure 11.19 – Drive Status 2 (210) ........................................................ 11-59Figure 11.20 – Drive Alarm 1 (211)......................................................... 11-60Figure 11.21 – Drive Alarm 2 (212)......................................................... 11-60Figure 11.22 – Start Inhibits (214)........................................................... 11-61Figure 11.23 – Dig In Status (216) .......................................................... 11-62Figure 11.24 – Dig Out Status (217) ....................................................... 11-63Figure 11.25 – Status 1 @ Fault (227).................................................... 11-65Figure 11.26 – Status 2 @ Fault (228).................................................... 11-65Figure 11.27 – Alarm 1 @ Fault (229) .................................................... 11-66Figure 11.28 – Alarm 2 @ Fault (230) .................................................... 11-66Figure 11.29 – Fault Config 1 (238) ........................................................ 11-68Figure 11.30 – Alarm Config 1 (259)....................................................... 11-69Figure 11.31 – Drive Logic Rslt (271) ..................................................... 11-70Figure 11.32 – Manual Mask (286) ......................................................... 11-71Figure 11.33 – Stop Owner ..................................................................... 11-72Figure 11.34 – Manual Owner................................................................. 11-72Figure 11.35 – Anlg In Config (320) ........................................................ 11-76Figure 11.36 – Anlg In Sqr Root (321) .................................................... 11-76Figure 11.37 – Analog Out Config........................................................... 11-80Figure 11.38 – Anlg Out Absolute (341).................................................. 11-80

Figure 12.1 – Location of DC Bus Voltage Measuring Points ................... 12-2Figure 12.2 – Location of Precharge Status LED...................................... 12-3Figure 12.3 – Location of the Ready LED................................................. 12-4Figure 12.4 – Sample Fault Screen on the LCD OIM ............................. 12-10Figure 12.5 – Accessing the Fault Queue............................................... 12-24Figure 12.6 – Sample Fault Queue Entry................................................ 12-24Figure 12.7 – Accessing the Fault Parameters ....................................... 12-25Figure 12.8 – Accessing the Drive Status Parameters ........................... 12-25Figure 12.9 – Accessing the Device Version Information ....................... 12-26

Contents VII

Figure 12.10 – Device Version Screens at Product and Component Levels............................................... 12-26Figure 12.11 – Accessing the OIM Version Information ......................... 12-27Figure 12.12 – OIM Version Screens at the Product and Component Levels............................................... 12-27Figure 12.13 – Accessing the Device Item Information .......................... 12-27

VIII SP600 AC Drive User Manual

Contents IX

List of Tables

Table 2.1 – Power Ratings.......................................................................... 2-3Table 2.2 – Power Ratings.......................................................................... 2-4Table 2.3 – SP600 AC Drive EN1800-3 EMC Compatibility ..................... 2-18Table 2.4 – Identification of Drive Connections ........................................ 2-19Table 2.5 – Standard Kits and Options..................................................... 2-21Table 2.6 – Remote OIM Model Number and Instruction Manual Number ................................................................... 2-21Table 2.7 – PC-Based Utility Model Number and Instruction Manual Number ................................................................... 2-22

Table 4.1 – Recommended Shielded Wire ................................................. 4-3Table 4.2 – Power Terminal Block Specifications....................................... 4-3Table 4.3 – Recommended Signal and Control Wire.................................. 4-5Table 4.4 – AC Line Input Fuse Selection Values ................................... 4-10Table 4.5 – AC Line Input Fuse Selection Values ................................... 4-11

Table 6.1 – Terminal Tightening Torques................................................... 6-2Table 6.2 – AC Line Reactors..................................................................... 6-3Table 6.3 – Power Terminal Descriptions................................................... 6-6

Table 7.1 – Wiring Signal and Control I/O to the Terminal Block................ 7-3Table 7.2 – Parameter Configuration for Figure 7.1 Wiring Example ......... 7-8

Table 9.1 – Quickstart Parameters ............................................................. 9-3

Table 11.1 – Parameter List...................................................................... 11-2Table 11.2 – Default Values for Preset Speeds 1-7................................ 11-25Table 11.3 – Sleep-Wake Mode ............................................................. 11-47Table 11.4 – Dynamic User Set Mode.................................................... 11-56Table 11.5 – Analog Output Scaling ....................................................... 11-82Table 11.6 – Speed Select Inputs........................................................... 11-84Table 11.7 – Default Values for Parameters 361-366............................. 11-84Table 11.8 – Drive Response to Jog Forward and Jog Reverse Inputs . 11-86Table 11.9 – Effect of Speed Select Input State on Selected Reference11-88

Table 12.1 – Precharge Board LED Indicators ......................................... 12-3Table 12.2 – Ready LED Status Definitions.............................................. 12-4Table 12.3 – Types of Alarms................................................................... 12-5Table 12.4 – Alarm Descriptions............................................................... 12-6Table 12.5 – Alarm Names Cross-Referenced by Alarm Numbers .......... 12-8Table 12.6 – Fault Types .......................................................................... 12-9Table 12.7 – Fault Descriptions and Corrective Actions......................... 12-12Table 12.8 – Fault Names Cross-Referenced by Fault Number............. 12-18Table 12.9 – Drive Does Not Start From Terminal Block Logic .............. 12-19

X SP600 AC Drive User Manual

Table 12.10 – Drive Does Not Start From OIM.......................................12-20Table 12.11 – Drive Does Not Respond to Changes in Speed Command......................................................................12-21Table 12.12 – Motor and/or Drive Will Not Accelerate to Commanded Speed............................................................................12-22Table 12.13 – Motor Operation is Unstable ............................................12-22Table 12.14 – Stopping the Drive Results in a Decel Inhibit Fault ..........12-23Table 12.15 – OIM Cables ......................................................................12-23Table 12.16 – Drive Unit .........................................................................12-23

Introduction 1-1

CHAPTER 1Introduction

This manual is intended for qualified electrical personnel familiar with installing, programming, and maintaining AC drives.

This manual contains information on:

• Installing and wiring the SP600 drive

• Programming the drive

• Troubleshooting the drive

The latest version of this manual is available fromor http://www.reliance.com/docs_onl/online_stdrv.htm.

1.1 Manual Conventions

Parameter names: In most instances, parameter names are shown as the parameter name followed by the parameter number. For example: PI Control (125).

1.2 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office.

For technical assistance, call 1-864-284-5444. Before calling, please review the troubleshooting section of this manual and check the standard drives website for additional information. When you call this number, you will be asked for the drive model number and this instruction manual number. Also, please have your product version number ready (refer to chapter 12).

1-2 SP600 AC Drive User Manual

About the Drive 2-1

CHAPTER 2About the Drive

The SP600 AC drive is a pulse-width-modulated (PWM) drive that provides general purpose (sensorless vector or volts/hertz) regulation for a broad range of applications requiring adjustable speed control of motors.

This chapter provides information about the SP600 AC drive, including:

• Information on identifying the drive

• Descriptions of NEMA ratings

• Descriptions of features

• A description of drive connections and communication options

2.1 Identifying the Drive by Model Number

Each SP600 AC drive can be identified by its model number, as shown in figure 2.1. The model number is on the shipping label and the drive nameplate. The model number includes the drive and any factory-installed options. Model numbers and drive power ratings are provided in table 2.1.


2.2 Power and NEMA Enclosure Ratings

Each of the SP600 AC drives in the 6SB401 Series has a NEMA 1 rating:

• NEMA 1: Vented. Intended for general-purpose indoor applications.

Tables 2.1 and 2.2 provide a listing of the drives and their ratings.

Figure 2.1 – Identifying the Drive by Model Number

@480 VAC027 = 27 A, 20 HP/15 kW034 = 34 A, 25 HP/18.5 kW040 = 40 A, 30 HP/22 kW052 = 52 A, 40 HP/30 kW065 = 65 A, 50 HP/37 kW077 = 77 A, 60 HP/45KW096 = 96 A, 75 HP/55 kW125 = 125 A, 100 HP/55 kW156 = 156 A, 125 HP/90 KW180 = 180 A, 150 HP/110 KW248 = 248 A, 200 HP/132 KW

@575 VAC022 = 22 A, 20 HP/15 kW027 = 27 A, 25 HP/18.5 kW032 = 32 A, 30 HP/22 kW041 = 41 A, 40 HP/30 kW052 = 52 A, 50 HP/37 kW062 = 62 A, 60 HP/45 kW077 = 77 A, 75 HP/55 kW099 = 99 A, 100 HP/75 kW125 = 125 A, 125 HP/90 kW144 = 144 A, 150 HP/110 kW

A = 24 VDC I/O CardB = 120 VAC I/O Card

ReservedAlways = N

A = EMC FilterN = Without Filter

Bus RegulationT = TransistorN = None

6SB 4 01 - 027 C T A N A

6SB = SP600 Bookshelf

4 = 380-480 V5 = 575 V

01 = NEMA 1 / IP20

B = Blank OIMC = LCD OIM

About the Drive 2-3

Tabl

e 2.

1 –

Pow

er R

atin

gs

Mo

del

N

um

ber

Frame

Ou

tpu

t A

mp

sN

om

inal

Po

wer

R

atin

gs

Inp

ut

KVA

@

480

VAC

Inp

ut

Am

ps

@ 4

80

VAC

Wat

ts

Lo

ss @

4

kHz

@ 4

80

VAC

480

VAC

400

VAC

110%

OL

D

uty

150%

OL

D

uty

Co

nt

1 Min

3S

ecC

on

t1 Min

3S

eckW

HP

kWH

P-0

27xx

xxx

227

3344

3033

4515

2011

1520

.624

.839

4-0

34xx

xxx

234

40.5

5437

4560

18.5

2515

2025

.931

.244

1-0

40xx

xxx

340

5168

4356

7422

3018

.525

30.5

36.7

459

-052

xxxx

x3

5260

8056

6486

3040

2230

39.7

47.7

610

-065

xxxx

x3

6578

104

7284

112

3750

3040

49.6

59.6

717

-077

xxxx

x4

7797

.513

085

108

144

4560

3750

60.1

72.3

974

-096

xxxx

x5

9610

614

410

511

615

855

75-

-74

.990

.111

4677

116

154

8512

817

0-

-45

6060

.172

.397

4-1

25xx

xxx

512

513

816

312

513

816

355

100

--

97.6

117

1475

9614

416

896

144

168

--

4575

74.9

90.1

1146

-156

xxxx

x6

156

172

234

170

187

255

9312

5-

112

214

718

2712

518

825

014

021

028

0-

-75

100

109

131

1475

-180

xxxx

x6

180

198

270

205

220

289

110

150

--

141

169

2297

156

234

312

170

255

313

--

100

125

122

147

1827

-248

xxxx

x6

248

273

372

260

286

390

132

200

--

194

233

3270

1

180

270

360

205

305

410

--

110

150

141

169

2297

1

124

8 am

p dr

ives

rat

ed a

t 2 k

Hz


Refer to Appendix A for drive technical specifications.

2.3 Overview of SP600 Features

This section provides an overview of the features in the SP600 AC drive.

2.3.1 Analog Inputs

There are two general-purpose analog inputs that can be configured either as voltage (±10 VDC or current (4-20 mA) inputs. These inputs are configured via parameters to provide some flexibility.

The analog inputs provide input signals that can be used for the following purposes:

• Provide a value to Speed Ref A (Speed Ref A Sel (90))

• Provide a trim signal to Speed Ref A (Trim in Sel (117))

Table 2.2 – Power Ratings

Model Number

Fra

me

Output AmpsNominal Power

RatingsInput KVA @

575 VAC

Input Amps

@575 VAC

Watts Loss

@4 kHz

@575 VAC

575 VAC110% OL

Duty150% OL

Duty

Cont1

Min3

Sec kW HP kW HP-022xxxxx 2 22 25.5 34 15 20 11 15 20.1 20.2 334-027xxxxx 2 27 33 44 18.5 25 15 20 24.7 24.8 376-032xxxxx 3 32 40.5 54 22 30 18.5 25 29.3 29.4 408-041xxxxx 3 41 48 64 30 40 22 30 37.4 37.6 552-052xxxxx 3 52 61.5 82 37 50 30 40 47.5 47.7 689-062xxxxx 4 62 78 104 45 60 37 50 58 58.2 797-077xxxxx 5 77 85 116 55 75 - - 72 72.3 1653

63 94 126 - - 45 60 58 58.2 910-099xxxxx 5 99 109 126 75 100 - - 92.5 92.9 2243

77 116 138 - - 55 75 72 72.3 1752-125xxxxx 6 125 138 188 90 125 - - 116.5 117 2386

99 149 198 - - 75 100 92.6 93 2336-144xxxxx 6 144 158 216 110 150 - - 134.5 135 2836

125 188 250 - - 90 125 116.7 117 2498

About the Drive 2-5

• Provide a reference when the terminal block has assumed manual control of the reference (TB Man Ref Sel (96))

• Provide the reference and feedback for the process PI loop (PI Ref Sel (126) and PI Feedback Sel (128))

• Provide an external value for the current limit and DC braking level (Current Limit Sel (147) and DC Bake Lvl Sel (157))

• Enter and exit sleep mode (178 to 183))

Refer to the parameter descriptions in chapter 11 for more information about configuring the analog inputs.

2.3.2 Analog Outputs

The drive has one analog output that can be used as a voltage (-10 to 10 V) or current (4-20 mA) signal to annunciate a wide variety of drive operating conditions and values. Select the source for the analog output by setting Analog Out1 Sel (342).

Refer to parameter 342 in chapter 11 for the analog output source options.

2.3.3 Digital Outputs

The SP600 drive provides two relay outputs for external annunciation of a variety of drive conditions. Each relay is a Form C (1 N.O. - 1 N.C. with shared common) device whose contacts and associated terminals are rated for a maximum of 250 VAC or 220 VDC.

See parameters 380 and 384 in chapter 11 for the drive conditions that can be annunciated.

2.3.4 Multiple Control Modes

The SP600 drive provides a number of user-selectable control modes to suit different applications:

• Sensorless Vector

• Sensorless Vector Economizer

• Custom Volts per Hertz

• Fan and Pump volts per Hertz

See the parameter description for Torque Perf Mode (53) in chapter 11 for details of operation of each control mode.


2.3.5 Multiple Stop Methods

There are several stop methods that can be selected using drive parameters 155 and 156:

• Coast to Stop

• Brake to Stop

• Ramp to Stop

• Ramp to Hold

Refer to the parameter descriptions in chapter 11 for more information about these stop mode selections.

Another stop method, dynamic braking, uses an optional internal or external DB braking resistor to dissipate stopping energy. See parameters 161 to 163 for more information about this feature.

2.3.6 Multiple Speed Control Methods

The purpose of speed regulation is to allow the drive to adjust to certain operating conditions, such as load change, and compensate for these changes in an attempt to maintain motor shaft speed within the specified regulation percentage.

The Speed Mode parameter (80) selects the speed regulation method for the drive, and can be set to one of 3 choices

• Open Loop - No speed control is offered

• Slip Comp - Slip Compensation is active

• Process PI - The PI loop sets the actual speed based on process variables.

Refer to parameter 80 in chapter 11 for more information.

2.3.7 Auto/Manual Reference Selection

You can override the selected “auto” reference by either toggling a function key on the OIM or asserting a digital input (Digital In”x” Sel (361 to 366)) that has been configured for Manual. This provides a source for local speed reference control even if a process input signal is the primary speed reference source.

Refer to the parameter descriptions in chapter 11 for more information.

About the Drive 2-7

2.3.8 Seven Preset Frequency Setpoints

There are seven preset frequency parameters (101 to 107) that are used to store a discrete frequency value. This value can be used for a speed reference or process PI reference. When used as a speed reference, they are selected via the digital inputs or the DPI (network) reference command. Refer to the parameter descriptions in chapter 11 for more information.

2.3.9 Motor-Operated Potentiometer (MOP) Function

The Motor-Operated Pot (MOP) function is one of the sources for the frequency reference (selected in parameter 90). The MOP function uses digital inputs to increment or decrement the speed reference at a programmed rate.

The MOP has these components:

• MOP Rate parameter (195)

• Save MOP Ref parameter (194)

• MOP Frequency parameter (11)

• MOP increment input (parameters 361 to 366)

• MOP decrement input (parameters 361 to 366)

2.3.10 Auto Restart (Reset/Run)

The Auto Restart feature, enabled in parameter 174 (Auto Rstrt Tries), provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows for automatic restart in applications where the drive is used in remote or "unattended" operation.

Important: Only certain faults are allowed to be auto reset. Faults that indicate possible drive malfunction are not resettable. Caution should be used when enabling this feature, since the drive will attempt to issue its own start command based on user-selected programming.

Refer to the descriptions of parameters 174 and 175 in chapter 11 for more information about using the Auto Restart feature.


2.3.11 Autotune

The Autotune feature, enabled in parameter 61 (Autotune), identifies the motor flux current and stator resistance for use in Sensorless Vector Control and Economizer modes (selected in parameter 53). The result of the flux current test procedure is stored in the Flux Current parameter (63), and the product of Flux Current Ref (63) and stator resistance is stored in IR Voltage Drop (62).

There are three options for autotuning:

• Static - the motor shaft will not rotate during this test.

• Dynamic - the motor shaft will rotate during this test.

• Calculate - tuning data is selected based on the motor nameplate data entered.

The static test determines only stator resistance, while the dynamic Autotune procedure determines both the stator resistance and motor flux current.

IR Voltage Drop (62) is used by the drive to provide additional voltage at all frequencies to offset the voltage drop developed across the stator resistance. An accurate calculation of the IR Voltage Drop will ensure higher starting torque and better performance at low speed operation.

If it is not possible or desirable to run the Autotune tests, there are two other methods for the drive to determine the IR Voltage Drop and Flux Current parameters. One method retrieves the default parameters stored in the drive EEPROM, and the other method calculates them from the user-entered motor nameplate data parameters.

If the stator resistance and flux current of the motor are known, you can calculate the voltage drop across the stator resistance and directly enter these values into the Flux Current and IR Voltage Drop parameters.

Refer to the description of the Autotune parameter (61) in chapter 11 for more information about using this feature.

2.3.12 Drive Protection Current Limit

There are six ways that the drive protects itself from overcurrent or overload situations:

• Instantaneous overcurrent trip

• Software Instantaneous trip

About the Drive 2-9

• Software current limit

• Heatsink temperature protection

• Overload protection IT (see Drive Overload Protection, section 2.3.13)

• Thermal manager

2.3.13 Drive Overload Protection

The drive thermal overload will protect the drive power stage while maintaining performance as long as the drive temperature and current ratings are not exceeded.

The drive will monitor the temperature of the power module based on a measured temperature and a thermal model of the IGBT. As the temperature rises, the drive may lower the PWM frequency to decrease the switching losses in the IGBT. If the temperature continues to rise, the drive may reduce current limit to try to decrease the load on the drive. If the drive temperature becomes critical, the drive will generate a fault.

If the drive is operated in a low ambient condition, the drive may exceed rated levels of current before the monitored temperature becomes critical. To guard against this situation, the drive thermal overload also includes an inverse time algorithm. When this scheme detects operation beyond rated levels, current limit may be reduced or a fault may be generated.


2.3.14 Motor Overload Protection

The motor thermal overload function (enabled in parameter 238) uses an inverse time (IT) algorithm to model the temperature of the motor. This curve is modeled after a Class 10 protection thermal overload relay that produces a theoretical trip at 600% motor current in ten (10) seconds and continuously operates at full motor current.

The following parameters are used to set the overload feature:

• Motor NP FLA (42)

• OL Factor (48)

• Motor OL Hertz (47)

• Fault Config 1 (238)

Refer to parameter 42 in chapter 11 for more information about this feature.

2.3.15 .Shear Pin Fault

This feature allows you to program the drive to fault if the drive output current exceeds the programmed current limit (see parameter 238). As a default, exceeding the set current limit is not a fault condition. However, if you want to stop the process in the event of excess current, the Shear Pin feature can be activated. By programming the drive current limit value and enabling the electronic shear pin, the drive will fault if excess current is demanded by the motor

2.3.16 .Drives Peripheral Interface (DPI)

SP600 drives support Drive Peripheral Interface (DPI) communication protocols for the primary interface and drive control. The DPI interface is an enhanced serial communications protocol that provides high functionality and high performance.

The serial DPI connection is used for devices such as Operator Interface Modules (OIMs), PC interface tool (VS Utilities), and network communication modules.

About the Drive 2-11

2.3.17 Network Data Transfer via Datalinks

A Datalink (see parameters 300 to 317) is one of the mechanisms used by SP600 drives to transfer data to and from a programmable controller via the optional network interface modules (e.g. DeviceNet or ControlNet). In the case of ControlNet, Datalinks allow a parameter value to be changed without using an Explicit Message or Block Transfer.

Each Datalink (e.g. A1, A2 for Datalink A) transfers two 16-bit values (A1, A2). If a 32-bit value needs to be transferred, each of the two 16-bit Datalinks must be set to the same parameter. One Datalink transfers the lower 16 bits; the other, the upper 16 bits.

For example, to set up the drive to receive accel and decel times from the connected PLC you would make the following parameter settings:

Data In A1 (300) = 140 (the parameter number of Accel Time 1)Data In A2 (301) = 142 (the parameter number of Decel Time 1)

2.3.18 Programmable Parameter Access Levels and Protection

The SP600 drive allows you to limit the number of parameters that can be viewed on the LCD OIM using an Access Level password. By limiting the parameter view to the most commonly adjusted set, additional features that may make the drive seem more complicated are hidden.

If you are trying to gain access to a particular parameter and the OIM skips over it, you must change the parameter view from "Basic" to "Advanced." This can be accomplished by reprogramming Param Access Lvl (196) to "Advanced". See section 10.3.1 for instructions.

2.3.19 Process PI Loop

The internal process PI function (see parameters 124 to 138) provides closed-loop process control with proportional and integral control action. The PI function reads a process variable input to the drive and compares it to a desired setpoint stored in the drive. The algorithm will then adjust the output of the process PI regulator thereby changing drive output frequency to try to make the process variable equal the setpoint.

Refer to the descriptions of parameters 124 and 138 in chapter 11 for more information.


2.3.20 S Curve

The S Curve function of SP600 drives allows control of the "jerk" component of acceleration and deceleration through user adjustment of the S Curve parameter (146). Jerk is defined as the rate of change of acceleration and/or deceleration. By adjusting the percentage of S Curve applied to the normal accel/decel ramps, the ramp takes the shape of an "S" allowing a smoother transition that produces less mechanical stress and smoother control for light loads.

Refer to the description of parameter 146 in chapter 11 for more information.

2.3.21 Three Skip Bands (Avoidance Frequencies)

The skip band function (see parameters 84 to 87 in chapter 11) provides three skip bands (also called avoidance frequencies) that the drive will ramp through but will not continuously run within. You can set the skip frequency (center frequency) and bandwidth of each band.This function is used to avoid mechanical resonance operating setpoints.

2.3.22 Flying Start

The flying start feature (enabled in parameter 169) is used to start into a rotating motor as rapidly as possible and resume normal operation with a minimal impact on load or speed. This action will prevent an overcurrent trip and significantly reduce the time for the motor to reach its desired frequency. Since the motor is "picked up" smoothly at its rotating speed and ramped to the proper speed, little or no mechanical stress is present.

Refer to the description of parameter 169 in chapter 11 for more information.

2.3.23 Voltage Class

The voltage class (see parameter 202 in chapter 11) identifies the general input voltage to the drive. This general voltage includes a range of actual operating voltages. A 400 volt class drive will have an acceptable input voltage range of 380 to 480 VAC. A 575 volt class will have a range of 475 to 632 volts.

While the hardware remains the same within each class, other variables, such as factory defaults and power unit ratings, will change. In most cases, all drives within a voltage class can be reprogrammed to accommodate a motor within its voltage class. This can be done by resetting the Voltage Class parameter to a different setup within the voltage class.


As an example, consider a 480 volt drive. This drive comes with factory default values for 480 V, 60 Hz, with motor data defaulted for U.S. motors (HP rated, 1750 RPM, etc.) By setting the Voltage Class parameter to "low voltage" (this represents 400 V in this case) the defaults are changed to 400 V, 50 Hz settings with motor data for European motors (kW rated, 1500 RPM, etc.).

2.3.24 Motor Cable Lengths

The length of cable between the drive and motor may be limited for various application reasons. The primary areas of concern are:

• Reflected wave

• Cable charging

The reflected wave phenomenon, also known as transmission line effect, produces very high peak voltages on the motor due to voltage reflection. While Reliance Electric drives have patented software that limits the voltage peak to 2 times the DC bus voltage and reduce the number of occurrences, many motors have inadequate insulation systems to tolerate these peaks.

Caution should be taken to understand the effects and restrictions when applying the drive to extended motor lead length applications. Proper cable type, motor and drive selection is required to minimize the potential risks.

2.3.25 Economizer Mode

Economize mode consists of operating the drive in sensorless vector control mode with an energy saving function (E-SVC). When the drive is in this mode and operating at steady state output frequency, the output voltage is automatically adjusted as the load is increased or decreased. This is done so that minimum current is supplied to the motor thereby optimizing its efficiency. By adjusting the output voltage, the flux producing current is reduced, but only if the total drive output current does not exceed 75% of motor rated current. In this mode the flux current is not allowed to be less than 50% of the selected flux current parameter value.

2.3.26 Fan Curve

When Torque Perf Mode (53) is set to Fan/Pump V/Hz the relationship between frequency and voltage is a square function where the voltage is proportional to frequency. The fan curve provides the option to generate voltage that is a function of the stator frequency squared up to the motor nameplate frequency. Above base frequency, the voltage is a linear function of frequency. At low speed, the fan curve can be offset by the Run Boost (70) parameter to provide necessary starting torque.


2.3.27 Programmable Parameter Access Levels and Protection

The SP600 drive allows you to limit the number of parameters that can be viewed on the LCD OIM using an Access Level password. See section 10.3.1 for more information about this password.

You can also protect parameters from unauthorized changes by activating the Write Protect password. See section 10.4 for more information about this password.

2.3.28 User Sets

2.3.28.1Normal Mode

After a drive has been configured for a given application, you can store a copy of all of the parameter settings in a specific EEPROM area known as a user set. Up to three user sets can be stored in the drive’s memory to be used for backup, batch switching, or other needs. All parameter information is stored. You can then recall this data to the active drive operating memory as needed. Each user set can also be identified with a user-selected name.

You can use this feature using any of the following methods:

• Set parameters Load Frm Usr Set (198) and Save To User Set (199). Refer to the parameter descriptions in chapter 11.

• Program the function keys on the LCD OIM. Refer to section B.3.1 for this procedure.

• Access the Memory Storage menu on the LCD OIM. Refer to section B.7.2.

Figure 2.2 – Normal Mode Operation


2.3.28.2Dynamic Mode

Dynamic Mode Operation allows User Sets to be loaded by utilizing digital input states or by writing a value to a user set select parameter (205). In this mode, the active area will no longer exchange data with any User Set, but the operating memory will be directly loaded with any one of the three User Sets.

Important: User Sets must be properly setup in Normal Mode before they can be loaded and used in Dynamic Mode.

The method of writing the user set select parameter (205) value will allow a communications network to control which User Set is in use. Digital inputs can be configured to allow local control of User Sets from the drive’s Terminal Block. Up to two digital inputs can be defined to allow selection of any combination of the three User Sets. Digital Inputs can be configured through Parameters 361 through 366.

The Dynamic Mode Operation User Set operation is enabled and disabled by a configuration parameter (204).

Important: Parameter writes are only recorded in the operating memory and not copied to non-volatile storage. Changes made to parameter values while Dynamic Mode is active will not be saved.

Parameter changes or power loss while Dynamic Mode is disabled (Normal Mode) will still automatically save changed data to active area non-volatile storage. Loading of User Set data to operating memory can occur only while the drive is in a stop condition. If a Dynamic Mode command from digital inputs occurs while the drive is running, the transfer of the selected User Set data will not occur until the drive is stopped, assuming that the Dynamic Mode and the transfer command are both still active when the drive stops. A Dynamic Mode command from the user set select parameter (205) while the drive is running will be immediately rejected.

Typical Setup / Operation:

Step 1. While in normal mode (Dyn UserSet Cnfg (204) = x0), enter data into drive and save to User Set using Save to User Set (199). Repeat for each needed User Set. Check that Dynamic User Set related Digital Inputs (parameters 361-366) and Datalink Inputs (parameters 300-307) are programmed the same in each.

Step 2. Enable Dynamic User Set Mode (Dyn UserSet Cnfg (204) = x1).

Step 3. Test restoring each programmed user Set via digital Inputs or DynUsrSetSel (205). If a Fault or Type 2 Alarm


occurs (Drive Alarm 2 (212) is non-zero), the User Set causing the error is loaded (see Dyn UserSet Actv (206) for indication). Return to Normal Mode (Dyn UserSet Cnfg (204) = x0), correct the Digital Input or Datalink definition(s), and save to the User Set that was loaded. Repeat step 2.

Step 4. Begin normal drive operation. Remember that User Sets can only be loaded while the drive is stopped.

At power-up, the drive will load operating memory with the values contained in the active non-volatile storage as part of initialization. If Dynamic Mode is Enabled, the selected User Set data will be loaded and processed after drive initialization completes but before the drive is allowed to become active. If Dynamic Mode is active and drive power is removed, User Set data will not be saved and any parameter changes will be lost.

When Dyn UserSet Cnfg (204) is set to Enabled, the drive will immediately transfer the selected User Set to operating memory as determined by digital inputs or DynUsrSetSel (205). The drive will verify that the User Set digital input configuration is identical in all three sets.

To avoid operational conflict between User Set values, all digital inputs must be set identically in each user set. If the digital inputs in each user set are not set identically, a Type 2 alarm is generated. The condition(s) must be corrected before the drive can become active.

Load Frm Usr Set (198) and Save to User Set (199) commands are not permitted in Dynamic Mode because these operations define data transfer between the active memory and the User Sets.

Disabling Dynamic Mode will cause the drive to operate in Normal Mode and parameter values will be transferred from operating memory into the active non-volatile storage area.

Figure 2.3 – Dynamic Mode Operation


2.4 CE Conformity

Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. The 400 volt class SP600 AC drive complies with the EN standards listed below when installed according to this User Manual.

CE Declarations of Conformity are available online at:http://www.reliance.com/certification.

Low Voltage Directive (73/23/EEC)

• EN50178 Electronic equipment for use in power installations

• EN60204-1 Safety of machinery – Electrical equipment of machines

EMC Directive (89/336/EEC)

• EN61800-3 (Second Environment) Adjustable-speed electrical power drive systems Part 3: EMC product standard including specific test methods

General Notes

To be CE-compliant, the motor cable should be kept as short as possible in order to avoid electromagnetic emission as well as capacitive currents.

AC drives may cause radio interference. The user is required to take measures to prevent interference.

If the adhesive label is removed from the top of the drive, the drive must be mounted in a cabinet with side openings less than 12.5 mm (0.5 in) and top openings less than 1.0 mm (0.04 in) to maintain compliance with the Low Directive.

Conformity with CE EMC requirements does not guarantee that the entire machine or installation will comply with the requirements.

Use of line filters in ungrounded systems is not recommended.


2.4.1 Essential Requirements for CE Compliance

All conditions listed below must be satisfied for SP600 drives to meet the requirements of EN61800-3 for the Second Environment (Industrial).

• Standard SP600 CE-compatible drive.• Grounding as described in section 5.3 if this manual.• Output power, control (I/O) and signal wiring must be braided,

shielded cable with a coverage of 75% or better, metal conduit or equivalent attenuation.

• Cable length restrictions, common mode cores and filters per table 2.2.

Table 2.3 – SP600 AC Drive EN1800-3 EMC Compatibility

Fra

me

Drive Description Second Environment

First Environment Restricted

Distribution

2 Drive with any options

Restrict Motor Cable to 30 m (98 ft)

- Restrict Motor Cable to 150 m (492 ft)

- Install external filter1

1 Select the Deltron Emcom (http://www.deltron--emcom.com) filter (or equivalent) that meets your specifications from the list below.

Filter Part No. Current Filter Part No. Current MIF306 6 A MIF350 50 A MIF310 10 A MIF375 75 A MIF316 16 A MIF3100 100 A MIF323 23 A MIF3150 150 A MIF330 30 A

3 Drive with any options

456

Drive with any options (Not Available)


2.5 Drive Connections

Figure 2.4 shows the locations of the drive terminal blocks and connectors used to set up and operate the drive. Table 2.3 identifies the drive connections shown with the corresponding number in figure 2.2.

Table 2.4 – Identification of Drive Connections

No. Connector Description

� Power Terminal Block

Connections for input and output power wiring.

� Signal and I/O Terminal Block

Connections for signal and I/O wiring.

Important: The I/O board may be 24 VDC or 115 VAC. Check the model number on the drive nameplate.

� DPI Port 1 OIM connection.

�DPI Port 2 Connection for remote OIM or RECOMM-232

serial interface.

�DPI Port 5 Connection for optional communications

module.


Figure 2.4 – Drive Connections

BR1 B

SHLD SHLD

V/T2 W/T3 PE R/L1 S/L2 T/L3

AUX IN+ AUX OUT–

OptionalCommunications

Module

75C Cu Wire6 AWG [10MM2] Max.

12 IN. LBS.1.4 N-M } TORQUE

WIRESTRIP

CO

NTR

OL

POW

ER

�

�

Frame 2

�

�

WIRE RANGE: 14-1/0 AWG (2.5-35 MM2)TORQUE: 32 IN-LB (3.6 N-M)STRIP LENGTH: 0.67 IN (17 MM)USE 75° C CU WIRE ONLY

POWER TERMINAL RATINGS

WIRE RANGE: 6-1/0 AWG (16-35 MM2)TORQUE: 44 IN-LB (5 N-M)STRIP LENGTH: 0.83 IN (21 MM)

GROUND TERMINAL RATINGS (PE)

300 VDC EXT PWR SPLY TERM (PS+, PS-)

WIRE RANGE: 22-10 AWG (0.5-4 MM2)TORQUE: 5.3 IN-LB (0.6 N-M)STRIP LENGTH: 0.35 IN (9 MM)

17

21

INPUT ACOUTPUT


Module

9

�

Frame 5

�

�


Module

L2L1T3T2T1 L3INPUTOUTPUT

USE 75 CCOPPER WIRE

ONLYTORQUE52 IN-LB(6 N-M)

BR2

PS

+P

S–

BR1 DC+ DC–USE 75 C COPPER WIRE ONLY, TORQUE 52 IN-LB (6 N-M)

22-10AWG

5.3 IN-LB(0.6 N-M)

WIR

E S

TRIP

Frame 6

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3


Module

PE B

PE A



WIRESTRIP

CONT

ROL

POW

ER

AUX IN+ –

SHLD

SHLD

PE


BR1 BR2


Frames 3 & 4

�

�

�

�

�

�

�

�

� �


2.6 Drive Communication Options

The flat-ribbon cable connector (labeled � in figure 2.2) is a parallel bus connection port that provides a means of attaching optional communication modules such as the DeviceNet Communication module to the SP600 AC drive.

Refer to the appropriate board instruction manual for more information. See table 2.5 for a list of available communication options.

2.7 Remote Operator Interface

The SP600 drive can be controlled and monitored using a remote LCD OIM (Operator Interface Module).

2.7.1 Connecting the Remote OIM or VS Utilities to the Drive

NEMA 1 Drives

The remote OIM connects to DPI port 2 at the bottom of the drive frame (labeled � in figure 2.2). Note that you must change the appropriate parameters (89 and 90) to enable control from the remote keypad.

Table 2.5 – Standard Kits and Options

Description Model NumberInstruction

Manual

DeviceNet Communication Module RECOMM-DNET D2-3478

Profibus Communication Module RECOMM-PBUS D2-3479

Interbus Communication Module RECOMM-IBUS D2-3480

ControlNet Communication Module RECOMM-CNET D2-3497

Ethernet/IP Communication Module RECOMM-ENET D2-3510

Modbus Communication Module RECOMM-H485 VT-1001-2

RS485 DF1 Communication Module RECOMM-485 D2-3514

Table 2.6 – Remote OIM Model Number and Instruction Manual Number


Manual

Remote NEMA 4X LCD OIM RE4LCD-PNL D2-3490

Small Remote NEMA 4X LCD OIM RE4ALCD D2-3525


2.8 PC-Based Utility

The SP600 drive can be configured using a PC-based software utility such as VS Utilities. This program enables you to upload and download parameter configurations.

Table 2.7 – PC-Based Utility Model Number and Instruction Manual Number


Manual

VS Utilities RECOMM-VSU232 D2-3488

Serial Converter (included with VS Utilities) for DPI Drives

RECOMM-232 D2-3477

Mounting the Drive 3-1

CHAPTER 3Mounting the Drive

This chapter provides information that must be considered when planning a SP600 AC drive installation and provides drive mounting information. Installation site requirements, drive requirements, and wiring requirements are presented.

!ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Use of power correction capacitors on the output of the drive can result in erratic operation of the motor, nuisance tripping, and/or permanent damage to the drive. Remove power correction capacitors before proceeding. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.


3.1 General Requirements for the Installation Site

It is important to properly plan before installing a SP600 AC drive to ensure that the drive’s environment and operating conditions are satisfactory. Note that no devices are to be mounted behind the drive. If air-cooled devices are mounted near the drive, the hot air exhaust may raise the ambient temperature level above what is allowed for safe operation of the drive.

The area behind the drive must be kept clear of all control and power wiring. Power connections may create electromagnetic fields which may interfere with control wiring or components when run in close proximity to the drive. Read the recommendations in the following sections before continuing with drive installation.

3.1.1 Verifying Power Module AC Input Ratings Match Available Power

SP600 drives are suitable for use on a circuit capable of delivering up to a maximum of 200,000 rms symmetrical amperes, and a maximum of 600 volts (nominal).

3.1.1.1 Unbalanced or Ungrounded Distribution Systems

For ungrounded distribution systems, disconnect the MOVs and common mode capacitors by removing or disconnecting the jumper(s) shown in figure 3.1.

!ATTENTION: To guard against personal injury and/or equipment damage caused by improper fusing or circuit breaker selection, use only the recommended line fuses/circuit breakers specified in section 4.4.

!ATTENTION: SP600 drives contain protective MOVs and common mode capacitors that are referenced to ground. To guard against drive damage, these devices should be disconnected if the drive is installed on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: To avoid electric shock hazard, verify that the voltage on the bus capacitors has discharged before removing/installing jumpers. Measure the DC bus voltage at the +DC terminal of the Power Terminal Block and the -DC test point. The voltage must be zero.


Frames Jumper Component No. Action

2-4 PEA Common Mode Capacitors

1 Remove jumper located above the Power Terminal Block.

PEB MOV’s 2 Same as above.

5

6

Wire Common Mode Capacitors

MOV’s

Input Filter Capacitors

3

4

Remove the I/O Cassette. The yellow/green jumper is located on the back of the chassis in the area shown. Disconnect, insulate and secure the wire to guard against unintentional contact with chassis or components.

Wire Common Mode Capacitors

MOV’s

Input Filter Capacitors

Remove the wire guard from the Power Terminal Block. Disconnect the three green/yellow wires from the two “PE” terminals shown. Insulate and secure the wires to guard against unintentional contact chassis or components.

Figure 3.1 – Typical Jumper Locations

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3

SHLD SHLD

PE R/L1 S/L2 T/L3

PE 2

MOV-PE JMPR

PE 1

AUX IN+ AUX OUT–



WIRESTRIP

CO

NTR

OL

POW

ER

PE 4 PE 3

DC FILTER CAP-PE JMPR

Frame 2

Frame 5

BR1 BR2 DC+ DC- U/T1 V/T2 W/T3 R/L1 S/L2 T/L3

PE B

PE A



WIRESTRIP

CO

NTR

OL

POW

ER

AUX IN+ –

SHLD

SHLD

PE


BR1 BR2








17

21

INPUT ACOUTPUT


Module

9

Frames 3 & 4

�

�

�

�

�

�


3.1.1.2 Input Power Conditioning

If any of the following conditions exist, the use of a line reactor or isolation transformer is recommended.

• Frequent power outages• Ungrounded AC supply source• Facility has power factor correction capacitors• Input voltage variations exceed drive operating specifications

3.1.1.3 AC Input Phase Selection (60HP and Larger)

Move the “Line Type” jumper as shown in figure 3.2 to select single or three-phase operation.

Important: When selecting single-phase operation, input power must be applied to the R (L1) and S (L2) terminals only.

3.1.1.4 Selecting/Verifying Fan Voltage (60HP and Larger)

Drives rated 60HP and larger use a transformer to match the input line voltage to the internal fan voltage. If your line voltage is different than the voltage class specified on the drive nameplate, it will be necessary to change the transformer tap as shown in figure 3.2. Common Bus (DC Input) drives require user supplied 120 or 240V AC to power the cooling fans. The power source is connected between “0 VAC” and the terminal corresponding to your source voltage.

The transformer is located behind the Power Terminal Block in the area shown in figure 3.2. Access is gained by releasing the terminal block from the rail. To release terminal block and change tap:

Step 1. Locate the small metal tab at the bottom of the end block.

Step 2. Press the tab in and pull the top of the block out. Repeat for next block if desired.

Step 3. Select appropriate transformer tap.

Step 4. Replace block(s) in reverse order.


3.1.2 Making Sure Environmental Conditions are Met

Before deciding on an installation site, consider the following guidelines:

• Verify that NEMA 1 drives can be kept clean, cool, and dry.• The area chosen should allow the space required for proper air

flow as defined in section 3.1.3.

• Be sure that NEMA 1 drives are away from oil, coolants, or other airborne contaminants.

• Do not install the drive more than 3300 feet above sea level without derating output power. For every 300 feet above 3300 feet, derate the output current 1%.

• Verify that the drive location will meet the environmental conditions in Appendix A.

Figure 3.2 – Selecting Input Phase and Fan Voltage (60HP and Larger)

480 Volt Tap

600 Volt Tap

690 Volt Tap

400 Volt Tap







17

21

INPUT ACOUTPUT


Module

9

Line Type

Thre

e-Ph

ase

(d

efault

)

Sing

le-Ph

ase

Spare

Spare

x 4


3.1.3 Minimum Mounting Clearances

Be sure there is adequate clearance for air circulation around the drive. For best air movement, do not mount SP600 AC drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring. See figure 3.3 for recommended air flow clearances.

Figure 3.3 – Minimum Mounting Clearances

101.6 mm(4.0 in)

101.6 mm(4.0 in)

50.8 mm(2.0 in)

(with adhesive label)

(without adhesive label)


3.1.4 Drive Dimensions and Weights

Overall dimensions and weights are illustrated in figures 3.4, 3.5, 3.6, and 3.7 as an aid to calculating the total area required by the SP600 AC drive.

Frame HP H W D A C Weight

2 20 to 25 @ 460 VAC20 to 25 @ 575 VAC

342.5(13.48)

222.0(8.74)

200.0(7.87)

320(12.6)

192.0(7.56)

12.52(27.6)

3 30 to 50 @ 460 VAC30 to 50 @ 575 VAC

517.5(20.37)

222.0(8.74)

200.0(7.87)

500(19.7)

192.0(7.56)

18.55(40.9)

Figure 3.4 – Panel-Mount Drive Dimensions - Frames 2 and 3

D

W

C15.0 (0.59)

5.8 (0.23) dia. 5.5 (0.22)

A

B5.5 (0.22)

H

HOT surfaces can cause severe burns

CAUTION

Dimensions in mm (in)Front View

Side View

Weight in kg (lb)



4 60 @ 460 VAC60 @ 575 VAC

758.8(29.87)

222.0(8.66)

201.7(7.94)

738.2(29.06)

192.0 (7.56)

24.49(54.0)

Figure 3.5 – Panel Mount Drive Dimensions - Frame 4

A

8.0(0.31)

H

7.0 (0.28) dia.

7.0 (0.28)3 Places

W

C15.0 (0.59)

Lifting Holes4 Places

D

Dimensions in mm (in)Front View

Side View

Weight in kg (lb)



5 60 to 100 HP @ 460 VAC60 to 100 HP @ 575 VAC

644.5(25.37)

308.9(12.16)

275.4(10.84)

625.0(24.61)

225.0(8.86)

37.19(82.0)

Figure 3.6 – Panel-Mount Drive Dimensions - Frame 5

HOT surfaces can cause severe burns

CAUTION

12.5(0.49)

6.5 (0.26)

259.1 (10.20)Detail

15.0 (0.59)

6.5 (0.26)

37.6 (1.48)

Lifting Holes - 4 Places12.7 (1.37) Dia.

H A

D

W

C



6 125 to 150 HP @ 460 VAC125 to 150 HP @ 575 VAC

976.3(38.43)

403.9(15.90)

275.5(10.85)

825.0(32.48)

300.0(11.81)

71.44(157.5)

6 200 HP @ 460 VAC200 HP @ 575 VAC

976.3(38.43)

403.9(15.90)

275.5(10.85)

825.0(32.48)

300.0(11.81)

75.07(165.5)

Figure 3.7 – Panel-Mount Drive Dimensions - Frame 6

A

13.5 (0.53)

126.3(4.97)

8.5 (0.33)

H

Lifting Holes4 Places

12.7 (0.50) Dia.

C

W

360.6 (14.20)Detail

18.0 (0.71)

8.5 (0.33)

49.6 (1.95)

D


3.2 Mounting the DriveRefer to figures 3.4, 3.5, 3.6, and 3.7 for drive mounting dimensions.

Attach the drive to the vertical surface using the mounting holes provided. Frame size 2 and 3 drives should be mounted using 3/16” (M5) bolts. Frame size 4 and 5 drives should be mounted using 1/4” (M6) bolts. Frame size 6 drives should be mounted using 5/16” (M8) bolts.

3.2.1 Verifying the Drive’s Watts Loss Rating

When mounting the drive inside another enclosure, determine the watts loss rating of the drive from tables 2.1 and 2.2. This table lists the typical full load power loss watts value at a carrier frequency of 4 kHz. (The 248 amp drive is rated at a carrier frequency value of 2 kHz.) Ensure that the enclosure is adequately ventilated with 0° to 40° C (32° to 104° F) ambient air.

Wiring Requirements for the Drive 4-1

CHAPTER 4Wiring Requirements

for the Drive

Wire size should be determined based on the size of conduit openings, and applicable local, national, and international codes, such as NEC/CEC. Evaluate wire sizes, branch circuit protection, and E-stop wiring before continuing with the drive installation.

4.1 Power Wiring

Cable Types Acceptable for 200-600 Volt Installations

General

A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits.

As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). See table 4.1.

!ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

!ATTENTION: National Codes and standards (NEC, VDE, BSI etc.) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.


Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 mils and should not have large variations in insulation concentricity.

Shielded/Armored Cable

Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strong consideration for shielded cable should be given in installations with sensitive equipment such as weigh scales, capacitive proximity switches, and other devices that may be affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communications/networking are also good candidates for shielded cable.

Shielded cable may also help reduce shaft voltage and induced bearing currents for some applications. In addition, the increased impedance of shielded cable may help extend the distance that the motor can be located from the drive without the addition of motor protective devices such as terminator networks.

Consideration should be given to all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. In addition, a braided shield should be included and be specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can greatly improve noise containment.

A good example of recommended cable is Belden 295xx (xx determines gauge). This cable has four (4) XLPE insulated conductors with a 100% coverage foil and an 85% coverage copper braided shield (with drain wire) surrounded by a PVC jacket. See table table 4.1.

Other types of shielded cable are available, but the selection of these types may limit the allowable cable length. Particularly, some of the newer cables twist 4 conductors of THHN wire and wrap them tightly with a foil shield. This construction can greatly increase the cable charging current required and reduce the overall drive performance. Unless specified in the individual distance tables as tested with the drive, these cables are not recommended and their performance against the lead length limits supplied is not known.


4.1.1 Power Wire Sizes

Input power wiring should be sized according to applicable codes to handle the drive’s continuous-rated input current. Output wiring should be sized according to applicable codes to handle the drive’s continuous-rated output current. See table 4.2 for the range of power wire sizes that the terminals can accommodate.

Table 4.1 – Recommended Shielded Wire

Location Rating/Type Description

Standard(Option 1)

600V, 90°C (194°F)XHHW2/RHW-2AnixterB209500-B209507,Belden 29501-29507,or equivalent

• Four tinned copper conductors with XLPE insulation.• Copper braid/aluminum foil combination shield and tinned copper drain wire.• PVC jacket.

Standard(Option 2)

Tray rated 600V, 90° C(194° F) RHH/RHW-2Anixter OLF-7xxxxx or equivalent

• Three tinned copper conductors with XLPE insulation.• 5 mil single helical copper tape (25% overlap min.) with three bare copper grounds in contact with shield.• PVC jacket.

Class I & II;Division I & II

Tray rated 600V, 90° C(194° F) RHH/RHW-2Anixter 7V-7xxxx-3Gor equivalent

• Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor.• Black sunlight resistant PVC jacket overall.• Three copper grounds on #10 AWG and smaller.

Table 4.2 – Power Terminal Block Specifications

FrameWire Size Range1

TorqueMaximum Minimum2 6 AWG 18 AWG 1.4 to 1.7 N-m (12 to 15 in-lb)3 3 AWG 14 AWG 1.8 to 3.8 N-m (16 to 32 in-lb)

4 1/0 AWG 8 AWG 4.0 N-m (12 in-lb)5 (60 to 75 HP) 1/0 AWG 12 AWG (2)

5 (100 HP) 2/0 AWG 4 AWG (2)

6 4/0 AWG 14 AWG 6.0 N-m (52 in-lb)

1 Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

2 Refer to terminal block label inside drive.


4.1.2 Using Input/Output Contactors

Input Contactor Precautions

Output Contactor Precaution

!ATTENTION: A contactor or other device that routinely disconnects and reapplies the AC line to the drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor. If an input device is used, operation must not exceed one cycle per minute or drive damage will occur.

ATTENTION: The drive start/stop/enable controlcircuitry includes solid state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. An auxiliary braking method may be required.

!ATTENTION: To guard against drive damage when using output contactors, the following information must be read and understood. One or more output contactors may be installed between the drive and motor(s) for the purpose of disconnecting or isolating certain motors/loads. If a contactor is opened while the drive is operating, power will be removed from the respective motor, but the drive will continue to produce voltage at the output terminals. In addition, reconnecting a motor to an active drive (by closing the contactor) could produce excessive current that may cause the drive to fault. If any of these conditions are determined to be undesirable or unsafe, an auxiliary contact on the output contactor should be wired to a drive digital input that is programmed as “Enable.” This will cause the drive to execute a coast-to-stop (cease output) whenever an output contactor is opened.


4.2 Control and Signal Wire Sizes

The terminal block on the SP 600 I/O interface board provides terminals for 24 V or 115 VAC power for the control inputs, depending on the I/O card installed in the drive. Refer to 4.3 for signal and control wiring specifications.

4.3 Recommended Motor Lead Lengths

Important: To reduce line disturbances and noise, motor lead length should not exceed 300 feet for any non-Reliance Electric motor or any non-inverter duty motor.

The length of cable between the drive and motor may be limited for various applications reasons. The primary reasons are:

• Reflected wave

• Cable charging

!ATTENTION: Verify the voltage rating of the I/O interface board before wiring any user devices. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Table 4.3 – Recommended Signal and Control Wire

Signal Type Wire Type(s) Description

Minimum Insulation

Rating

Analog I/O Belden 8760/9460 (or equiv.)

18AWG, twisted pair, 100% shield with drain1.

300V, 60°C (140°F)

Belden 8770(or equiv.)

18AWG, 3-conductor, shielded for remote pot only.

UnshieldedControl

Per US NEC or applicable local code

300V, 60°C (140°F)

ShieldedControl

Multi-conductor cable such as Belden 8770(or equiv.)

18 AWG, 3-conductor shielded.

300V, 60°C (140°F)

1 If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.


Typically, motor lead lengths less than 91 m (300 ft) are acceptable. The primary concerns regarding cable length are cable charging and reflected wave (see section 4.3.1).

When total lead length exceeds 300 feet, nuisance trips can occur caused by capacitive current flow to ground. Note that these capacitively-coupled currents should be taken into consideration when working in areas where drives are running. If the motor lead length must exceed these limits, the addition of output line reactors (see section 6.3.1) or other steps must be taken to avoid problems.

Your application may be restricted to a shorter lead length due to:

• the type of wire (shielded or unshielded)

• the placement of wire (for example, in conduit or a cable tray)

• the type of line reactor

• the type of motor.

• carrier frequency.

Figure 4.1 illustrates how to calculate motor lead lengths. The examples shown assume a maximum lead length of 300 feet.

4.3.1 Reflected Wave Compensation

You must understand the effects and restrictions when applying the drive to extended motor lead length applications. Proper cable type, motor and drive selection is required to minimize the potential risks.

Figure 4.1 – How to Calculate Typical Motor Lead Lengths

SP600Drive

Motor

150′ 150′100′

200′200’

50′ 50′

300′

Motor

Motor

MotorMotor Motor

Motor

SP600Drive

SP600Drive

SP600Drive


The reflected wave phenomenon, also known as transmission line effect, produces very high peak voltages on the motor due to voltage reflection. Voltages in excess of twice the DC bus voltage, (650 V DC nominal @480 V input) result at the motor and can cause motor winding failure.

While Reliance Electric drives have patented software that limits the voltage peak to 2 times the DC bus voltage and reduce the number of occurrences, many motors have inadequate insulation systems to tolerate these peaks.

The correction software modifies the PWM modulator to prevent PWM pulses less than a minimum time from being applied to th

20 hp to 200 hp @ 460 vac 20 hp to 150 hp @ 575 vac · instruction manual sp600 ac drive user...

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